JP2009241267A - Manufacturing method of laminated body - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a laminated body by which air bubbles can be prevented from being mixed for a long period of time when a broad transfer material is transferred while lowering friction with a roller according to the treating amount of press-contact and transfer. <P>SOLUTION: When an average value of static friction coefficients of a pressing roller, which brings the broad transfer material having a transfer layer on a temporary support into contact with a substrate by pressing, toward the temporary support is in a range between 0.25 and 0.7, press-contact is performed while keeping relative standard deviation of the static friction coefficients of the press-contact roller, which comes into contact with the temporary support, in a shaft center direction 0.25 or less. After press-contact, the temporary support is exfoliated and thereby the transfer layer is transferred onto the substrate to manufacture the laminated body. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a laminate using a transfer material having a transfer layer on a temporary support.

  For example, a liquid crystal panel substrate, a printed wiring substrate, a PDP panel substrate, and the like are known in which a photosensitive sheet body (web) having a photosensitive resin layer is attached to the substrate surface. The photosensitive sheet body used in the invention includes a sheet formed by providing a photosensitive resin layer and a protective film on a flexible plastic substrate.

  Such a photosensitive sheet body is generally attached to a region corresponding to the range of the photosensitive resin layer to be attached to the substrate while conveying a substrate such as a glass substrate or a resin substrate at a predetermined interval. The protective film is peeled off from the photosensitive sheet body, and the exposed surface of the photosensitive resin layer is brought into close contact with the substrate to be peeled and transferred.

  In peeling transfer of the photosensitive resin layer, if air is mixed or wrinkles occur between the substrate and the substrate, transfer defects such as peeling will occur later, and the final image may be defective. There is.

  In relation to the above transfer method, the static friction coefficient of the pressure roller with respect to the support that supports the photosensitive material layer is set in the range of 0.1 to 0.7, and the pressure roller is rotated to perform photosensitivity through the support. By pressing the material layer to the substrate, an appropriate slip occurs between the pressure roller and the support, and the support and the substrate are transported in a stable state for a long period of time, and the photosensitive material layer is not uneven. A method for producing a photosensitive laminate that is transferred to a substrate is disclosed (for example, see Patent Document 1).

Also, when the transfer film is superimposed on the substrate and pressed and bonded, the angle between the substrate and the supplied transfer film becomes an obtuse angle, or the pressing member of the pressing portion has a roller portion with a small diameter. There has been proposed a transfer method or the like for efficiently transferring by bonding using a roller and preventing the occurrence of defects due to air entrainment (see, for example, Patent Document 1).
JP 2006-23407 A JP-A-8-160216

However, even if transfer is performed with the static friction coefficient of the pressure roller with respect to the support set to a range of 0.1 to 0.7 as in the above-described photosensitive laminate manufacturing method, The dirt between the film and the friction between the film and the rubber pressure roller gradually decreases. Due to this reduction in friction, skew occurs during film conveyance, and wrinkles generated on the support that supports the photosensitive material layer become gradually stronger. This is more remarkable as the substrate size increases and the width of the laminate on the substrate increases, and the support that supports the photosensitive material layer is caused by film meandering (skew) caused by a reduction in friction when the photosensitive material layer is transferred to the substrate. Wrinkles and slack are generated and bubbles are involved, and the quality (lami quality) of the laminate obtained after lamination is impaired. For this reason, in order to withstand long-term use, methods such as lowering the lamination speed and stabilizing the quality of the laminate have been adopted, but the productivity is significantly reduced. Further, the skew as described above can be eliminated to some extent by adjusting the manufacturing conditions such as increasing the film tension, and the entrainment of bubbles can be reduced. However, if the film tension is increased, the photosensitive material layer can be cracked, and the cushion layer However, another problem arises that it becomes easy to peel off, resulting in density unevenness and the like, resulting in deterioration of quality. On the other hand, in recent years, the enlargement of liquid crystal panel substrates has been rapidly progressing, and it is desired to establish a technique capable of satisfactorily laminating to larger substrates.
The problem of wrinkles, slack, and air bubbles is likely to occur when transferring using a wide roll film having a width direction of, for example, 1000 mm or more, and becomes more apparent when the roll width becomes 1200 mm or more.

  In addition, in the above transfer method in which the angle between the substrate and the transfer film is made obtuse or a roller member having a small diameter is used as the pressing member, when a wide film is stuck on the substrate, the static friction on the rubber surface of the lami roll is changed. It cannot be expected to prevent the entrainment of bubbles.

  The present invention has been made in view of the above, and avoids the mixing of bubbles when transferring a wide transfer material, while the friction between the rollers decreases according to the amount of pressure bonding and transfer. An object of the present invention is to provide a method for producing a laminate that can prevent air bubbles from being mixed for a longer period of time than before, and to achieve the object.

  In the present invention, when a wide transfer material is pressure-bonded to a substrate and transferred, the pressure roller for pressure-bonding the transfer material to the substrate repeats the transfer so that the static friction with the temporary support is brought into contact with the temporary support. The coefficient decreases, and the decrease in static friction coefficient is not necessarily uniform in the width direction of the pressure roller, but is known to fluctuate due to variations in tension and temperature during pressure bonding. Furthermore, the width direction of the pressure roller surface in contact with the temporary support The distribution of the static friction coefficient is related to the entrainment of bubbles, and the knowledge that it can contribute to the reduction of bubbles in a specific range has been obtained and achieved based on such knowledge.

Specific means for achieving the above object are as follows.
<1> The average value of the coefficient of static friction (60 ° C., 55% RH) of the pressure support roller of the pressure roller for pressing a wide transfer material having a transfer layer on the temporary support to the substrate is 0.25 to 0 .7 when the relative standard deviation of the static friction coefficient (60 ° C., 55% RH) in the axial direction of the pressure roller in contact with the temporary support is maintained at 0.25 or less, and pressure bonding is performed. It is a method for manufacturing a laminate, in which the temporary support is peeled off after pressure bonding to transfer the transfer layer to the substrate to produce a laminate.

  <2> The method for producing a laminate according to <1>, wherein the surface of the pressure roller in contact with the temporary support is a rubber material.

  <3> The method for producing a laminate according to <1> or <2>, wherein the pressure bonding is performed by heating the pressure roller in a range of 80 to 150 ° C.

  <4> The transfer layer is a thermoplastic photosensitive resin layer exhibiting viscosity characteristics in a range of 30 to 30000 Pa · s when heated to a range of 80 to 150 ° C. by the pressure roller. It is the manufacturing method of the laminated body as described in any one of said <1>-<3>.

  According to the present invention, the friction between the roller and the roller is reduced in accordance with the processing amount of the pressure bonding / transfer, but the mixing of the bubbles is avoided when transferring the wide transfer material, and the bubbles are longer than before. The manufacturing method of the laminated body which can prevent mixing can be provided.

Hereinafter, the manufacturing method of the laminated body of this invention is demonstrated in detail.
In the method for producing a laminate of the present invention, the average coefficient of static friction at 60 ° C. and 55% RH with respect to the temporary support of the pressure roller for pressing a wide transfer material having a transfer layer on the temporary support to the substrate. When the value is in the range of 0.25 to 0.7, the relative standard deviation of the coefficient of static friction at 60 ° C. and 55% RH in the axial direction of the pressure roller in contact with the temporary support is 0.25 or less. The transfer material and the substrate are pressure bonded to each other, and the temporary support is peeled off after pressure bonding, whereby the transfer layer is transferred to the substrate to produce a laminate.

  In the present invention, when the transfer material used for transferring the layer is a wide-width transfer material (for example, 1000 mm or more in the width direction) having a transfer layer on the temporary support, the transfer material is contacted with the temporary support. Wear or dirt adheres to the surface of the pressure roller (for example, rubber-based roller) for contacting and pressing the transfer material to the substrate, and the average static friction coefficient between the pressure roller and the temporary support is within a predetermined range. When the transfer material is in a state where the transfer material slides on the roller surface and is likely to meander, the distribution of the static friction coefficient in the width direction (axial direction) of the pressure roller is a range in which the relative standard deviation is 0.25 or less. By maintaining the above, distortion of the force that occurs due to local slippage in the width direction of the roller surface is relieved, so that mixing of bubbles at the time of transfer is avoided, and highly uniform transfer processing can be performed. As a result, it is possible to form a high-quality image in which the occurrence of density unevenness is suppressed, and a long-term stable process is possible. Furthermore, the frequency of replacement of the pressure roller can be reduced, continuous operation over a long period of time is possible, and production efficiency is improved. This is particularly applicable to an increase in the size of a substrate, which is a transfer target, and is long for a substrate having a width corresponding to the width direction of the pressure roller, that is, a long side (width direction) of a rectangular substrate of 1000 mm or more. This is effective when the transfer material is subjected to pressure bonding and peeling transfer.

In the present invention, among the scenes in which the transfer material is superimposed and pressure-bonded on the substrate as the transfer target, the average value of the static friction coefficient (60 ° C., 55% RH) with respect to the temporary support of the pressure roller is 0.25 to 0.25. `` When 0.7 '' means a state in which the occurrence of meandering, and in turn, the occurrence of bubbles due to wrinkles, etc. is likely to occur. It is important in terms of long-term retention of treatment that can be prevented.
When the average value of the static friction coefficient is within the above range, the relative standard deviation of the static friction coefficient (60 ° C., 55% RH) in the axial direction of the pressure roller on the side in contact with the temporary support of the transfer material is 0.25. The following. When the relative standard deviation exceeds 0.25, the slipperiness of the roller surface is in a non-uniform state. Therefore, the distortion applied to the transfer material when meandering is not alleviated, wrinkles are generated, and bubbles are generated. It cannot be prevented. The relative standard deviation is preferably 0.15 or less from the viewpoint of preventing generation of bubbles.
The relative standard deviation is obtained by dividing the standard deviation by the average value.

The static friction coefficient in the present invention is a value measured by the following method at a temperature of 60 ° C. and a humidity of 55% RH. A method for measuring the static friction coefficient will be described with reference to FIG.
Specifically, as shown in FIG. 4, the pressure roller is held in a non-rotating state, and a photosensitive film 12 is applied so as to contact the outer peripheral surface in the range of the central angle of 90 ° of the pressure roller. The weight W is connected to one end of the film to give a tension of 140 N, and the box 59 is connected to the other end of the photosensitive film 12, and the pellet 61 is thrown into the box little by little, and the weight W is lifted. Is calculated from the total weight of the box body 59 and the pellet 61 and the weight of the weight W.
Further, the average value of the static friction coefficient is a value obtained by averaging the static friction coefficients obtained by measuring a total of 11 points at 100 mm intervals in the width direction (axial direction) of the pressure roller by the above method.

The relative standard deviation of the static friction coefficient can be reduced to 0.25 or less by, for example, a method of increasing the static friction coefficient of the pressure roller by surface treatment with an organic solvent.
The surface treatment can be performed by applying an organic solvent to the surface of the pressure roller, wiping off the excess organic solvent, and drying. The organic solvent is preferably an alcohol. The organic solvent is preferably ethanol or propanol from the viewpoint of rapid drying. The organic solvent may be used by mixing with water or the like, and the concentration of the organic solvent used is not particularly limited and may be appropriately selected according to the state of the roller surface.

  In the method for producing a laminate of the present invention, a wide transfer material having a transfer layer on a temporary support is used. If you try to transfer continuously using a wide roll material, for example, it may meander during transport, and during the meander, the transfer material will not be able to slide locally on the roller surface due to the friction between the rollers. There is. The “wide width” in the present invention means that the length of the transfer material in the width direction is 1000 mm or more, and is preferably 1250 mm or more in terms of the effects of the present invention.

When the transfer material is pressed against the substrate, the transfer material may be tensioned to prevent meandering. However, the transfer layer is cracked, and when the transfer material has a temporary support and a cushion layer between the transfer layers, a cushion is provided. The tension to the transfer material is preferably 80 to 200 N / mm, and more preferably 110 to 180 N / mm, from the viewpoint of easy peeling of the layer. When the tension is 140 N / mm or more, the effect of preventing meandering and, moreover, the effect of suppressing wrinkles and bubbles is higher, and when the tension is 100 N / mm or less, cracking of the transfer layer and peeling of the cushion layer can be avoided.
The tension of the transfer material is measured by a force gauge.

Here, the transfer material will be outlined.
The transfer material in the present invention is not particularly limited as long as it is configured by providing a temporary support and a transfer layer provided on the temporary support, and a known transfer material can be selected. An example of the transfer material is a transfer material in which a thermoplastic resin layer (cushion layer), an intermediate layer (oxygen barrier layer), and a photosensitive resin layer are laminated on a temporary support in order from the temporary support side. Also good.

The transfer material is produced, for example, by forming a thermoplastic resin layer and an intermediate layer sequentially on the temporary support from the temporary support side as necessary, and then providing a transfer layer such as a photosensitive resin layer. The A protective film may be further pressure-bonded and provided on the surface of the transfer layer. As a specific example, on a temporary support, a thermoplastic resin layer coating solution is applied, dried to provide a thermoplastic resin layer, and an intermediate layer coating solution that does not dissolve in the thermoplastic resin layer is applied thereon, After drying and laminating the intermediate layer, it can be obtained by applying and drying a photosensitive resin layer coating solution that does not dissolve in the intermediate layer and laminating the photosensitive resin layer. In addition, the surface of the thermoplastic resin layer and the intermediate layer are brought into contact with the sheet having the thermoplastic resin layer formed on the temporary support and the sheet having the photosensitive resin layer and the intermediate layer formed on the protective film. It is also possible to produce them by pasting them together.
Transfer layers such as a thermoplastic resin layer, an intermediate layer, and a photosensitive resin layer can be formed by applying a coating solution of a composition corresponding to each of the transfer layers by a known method. In the case of coating, for example, it can be formed using a coating apparatus such as a spinner, a wheeler, a roller coater, a curtain coater, a knife coater, a wire bar coater, and an extruder.

  The temporary support in the transfer material is preferably flexible and does not cause significant deformation, shrinkage or elongation even under pressure, or under pressure and heat. Examples of such a temporary support include a polyethylene terephthalate film, a cellulose triacetate film, a polystyrene film, a polycarbonate film, etc. Among them, a biaxially stretched polyethylene terephthalate film is particularly preferable.

Examples of the transfer layer in the transfer material include a photosensitive resin layer containing a colorant, a monomer, a polymerization initiator and the like, a thermoplastic resin layer (cushion layer) containing an acrylic resin, an intermediate layer containing polyvinyl alcohol and a polyvinylpyrrolidone component ( Oxygen barrier layer).
When the photosensitive resin layer is used as a transfer layer, as an example of the photosensitive resin layer, when a light blocking property such as a black matrix is required, the photosensitive black resin layer described in JP-A-2005-3861 or JP-A-2004-2004 is disclosed. Examples include layers formed using the colored composition described in Japanese Patent No. 240039, and color patterns such as red (R), green (G), and blue (B) (for example, colored pixels of a color filter). When forming, a layer formed using the colored photosensitive resin composition described in JP-A-2006-23696 is exemplified. For example, a photosensitive resin layer for forming a colored pattern such as RGB can be formed by applying a coating liquid for forming a photosensitive resin layer corresponding to a desired hue such as RGB on a temporary support.

  The photosensitive resin layer is preferably a thermoplastic photosensitive resin layer that exhibits viscosity characteristics in the range of 30 to 30,000 Pa · s when heated and melted in the range of 80 to 150 ° C. by the pressure roller. When the viscosity at the time of heating and melting is 30 Pa · s or more, substrate adhesion can be improved, and when it is 30,000 Pa · s or less, it is advantageous in that bubbles do not easily remain.

The transfer material may be provided with a thermoplastic resin layer between the temporary support and the transfer layer. The thermoplastic resin layer is provided with a cushioning property so as to follow the irregularities when the irregularities exist on the surface of the substrate, which is a transfer target. As a component constituting the thermoplastic resin layer, an organic polymer substance described in JP-A-5-72724 is preferable, and the polymer softening point according to the Viker Vicat method (specifically, American Materials Testing Method ASTM D1 ASTM D1235). It is particularly preferable that the softening point by the measurement method is selected from organic polymer substances having a temperature of about 80 ° C. or less.
Specifically, polyolefins such as polyethylene and polypropylene, ethylene copolymers such as ethylene and vinyl acetate or saponified products thereof, ethylene and acrylic acid esters or saponified products thereof, polyvinyl chloride, vinyl chloride and vinyl acetate and saponified products thereof. Such as vinyl chloride copolymer, polyvinylidene chloride, vinylidene chloride copolymer, polystyrene, styrene copolymer such as styrene and (meth) acrylic acid ester or saponified product thereof, polyvinyl toluene, vinyl toluene and (meth) acrylic acid Vinyl toluene copolymer such as ester or saponified product thereof, poly (meth) acrylate ester, (meth) acrylate copolymer such as butyl (meth) acrylate and vinyl acetate, vinyl acetate copolymer nylon, copolymer Polymerized nylon, N-al Kishimechiru nylon, polyamide resins such as N- dimethylamino nylon, and organic polymers like.

  The transfer material may be provided with an intermediate layer for the purpose of preventing mixing of components during application of a plurality of application layers and during storage after application. The intermediate layer is preferably an oxygen barrier layer having an oxygen barrier function described as “separation layer” in JP-A-5-72724. In this case, the sensitivity at the time of exposure is improved, the time load of the exposure machine is reduced, and the productivity is improved. As the oxygen barrier layer, a layer that exhibits low oxygen permeability and is dispersed or dissolved in water or an aqueous alkaline solution is preferable. For example, a layer containing polyvinyl alcohol and polyvinyl pyrrolidone is suitable.

  The protective film applied on the transfer layer may be the same or similar material as the temporary support, but is required to be easily separated from the transfer layer. By providing the protective film, the transfer layer can be protected from contamination and damage during storage. Examples of the protective film include silicone paper, polyolefin or polytetrafluoroethylene sheets and films. The thickness of the protective film is generally 5 to 100 μm.

  The board | substrate used for the manufacturing method of the laminated body of this invention is not restrict | limited in particular, For example, it can select as needed from well-known base materials, such as a glass plate, a resin-made sheet | seat and film, and resin-coated paper. it can. Among them, a transparent substrate is suitable, and examples thereof include a soda glass plate having a silicon oxide film on its surface, a low-expansion glass, a non-alkali glass, a known glass plate such as a quartz glass plate, or a plastic film. it can.

  When the substrate is subjected to a coupling process in advance, the adhesion between the substrate and the transfer material can be improved. As the coupling treatment, a method described in JP 2000-39033 A is suitable.

The size of the substrate in the present invention may be arbitrarily selected, but from the viewpoint of achieving the effect of the present invention, a substrate having a rectangular long side of 1000 mm or more is preferable, more preferably the long side (width direction). A form using a substrate having a size of 1300 mm × short side 1200 mm or more is preferable.
The thickness of the substrate is not particularly limited, but generally 700 to 1200 μm is preferable, and 500 to 1100 μm is more preferable.

  An embodiment using the laminate manufacturing apparatus shown in FIG. 1 for a process for producing a laminate by transferring a transfer layer to a substrate by pressure-bonding a wide transfer material to the substrate and peeling the temporary support after press-bonding. Will be described as an example. However, in this invention, it is not restrict | limited to the embodiment using this laminated body manufacturing apparatus.

  The laminated body manufacturing apparatus is supplied with the photosensitive film 12 having the laminated structure shown in FIG. 2 and the glass substrate 14, and the supplied photosensitive film is heat-pressed to the glass substrate surface as shown in FIG. Thus, a color filter substrate for a liquid crystal panel or a PDP panel is manufactured.

  The photosensitive film 12 is configured by laminating a temporary support 16, a photosensitive resin layer 18 colored in a predetermined color, and a protective film 20. The temporary support 16 is made of polyethylene terephthalate (PET) as a raw material, and an acrylic base coat containing an antistatic agent is applied to the outer surface thereof. The photosensitive resin layer 18 is a thermoplastic photosensitive resin layer that exhibits viscosity characteristics in the range of 30 to 30000 Pa · s (= 300 to 300000 poise) when heated and melted in the range of 80 to 150 ° C. by the pressure roller. is there. In the photosensitive film 12, half cut portions 27a and 27b are formed at predetermined intervals by a round blade described later.

  In the laminate manufacturing apparatus, the temporary support 16 is left on the film roll 22 for supplying the photosensitive film 12 from the upstream side, and the predetermined portions of the protective film 20 and the photosensitive resin layer 18 of the supplied photosensitive film 12. And a machining mechanism 26 that forms half-cut portions (27a, 27b; see FIG. 2) by cutting. Further, on the downstream side of the processing mechanism 26, there is a label (not shown) in which both ends are bonded to the adjacent protective film 20a via the protective film 20b, while the intermediate portion is formed in a non-adhered state with respect to the protective film 20b. A label adhering mechanism 34 for adhering the label to the protective film 20a is provided.

  Further downstream of the label adhesion mechanism 34, a reservoir mechanism 36 for changing the photosensitive film 12 from tact feeding to continuous feeding, a peeling mechanism 38 for peeling the protective film 20a from the photosensitive film 12, and a photosensitive film A tension control mechanism 40 that applies a predetermined tension to the belt 12 and a detection mechanism 42 that detects the half-cut portions 27a and 27b formed on the photosensitive film 12 as shown in FIG. A pressure bonding mechanism 44 for heat-pressing the photosensitive resin layer 18 of the photosensitive film 12 to the glass substrate 14 is disposed further downstream of the detection mechanism 42. In FIG. 1, the roller 46 is mounted so as to be swingable up and down, so that the speed difference between the tact transport on the upstream side of the photosensitive film and the continuous transport on the downstream side is absorbed. The protective film 20 a continuously peeled from the photosensitive film 12 via the peeling roller 50 is wound around the winding portion 52. The tension control mechanism 40 includes a cylinder 54 and a tension dancer 56.

  The pressure-bonding mechanism 44 includes pressure-bonding rollers 64 a and 64 b for heat-bonding the photosensitive resin layer 18 of the photosensitive film 12 to the upper surface portion of the glass substrate 14 supplied from the substrate transport mechanism 62. The substrate transport mechanism 62 includes a substrate heating unit 66 disposed so as to sandwich the glass substrate 14 and a transport unit 68 that transports the glass substrate 14.

  The pressure rollers 64 a and 64 b provided in the pressure mechanism 44 are heating rollers that heat the photosensitive film 12 and the glass substrate 14 at a temperature of 80 to 150 ° C. while pressure-bonding the photosensitive film 12 and the glass substrate 14 with a linear pressure in the range of 30 to 300 N / cm. Yes, rubber layers 65a and 65b are formed on the outer periphery of each pressure roller. Backup rollers 70a and 70b are slidably contacted with the pressure rollers 64a and 64b, respectively, and the backup roller 70b is pressed by the pressure cylinder 72 toward the backup roller 70a disposed above, and the pressure rollers 64a and 64b are pressed against each other. It has come to be.

  The pressure rollers 64a and 64b are provided with a drive mechanism for the pressure roller 64a located above the glass substrate. Conversely, the pressure roller 64b located below the glass substrate is driven by the driving force of the pressure roller 64a. It is configured. The driving roller is preferably on the side in contact with the photosensitive film 12, but both the pressure rollers 64a and 64b may be driven to rotate. The pressure rollers 64a and 64b convey the photosensitive film 12 and the glass substrate 14 at a speed of 1.0 to 10 m / min in a state where the photosensitive film 12 and the glass substrate 14 are pressure bonded.

  The rubber layers 65a and 65b are heat resistant rubbers having a hardness of 30 to 90 degrees according to JIS K 6253 type A (ISO 7619 type A), such as silicone rubber, CR (chloroprene rubber), IIR (butyl rubber), EPDM (ethylene). Propylene rubber), CSM (chlorosulfonated polyethylene rubber), fluororubber and the like can be used. Further, the surface of each rubber layer is subjected to a low friction treatment in order to adjust the static friction coefficient of the photosensitive film 12 with respect to the temporary support 16. In this case, examples of the friction reduction treatment include surface coating treatment, impregnation treatment, tube hanging, and surface polishing treatment.

Examples of the surface coating treatment include PTFE (polytetrafluoroethylene; registered trademark), PFA (tetrafluoroethylene perfluoroalkyl vinyl ether copolymer), and FEP (fluorinated ethylene propylene tetrafluoroethylene-hexafluoropropylene copolymer). ) System, ETFE (ethylene tetrafluoroethylene copolymer) system, ECTFE (ethylene chlorotrifluoroethylene copolymer) system, epoxy-modified system, fluorine system, etc. are applied to the rubber layer surface and heated. This is a baking process.
The impregnation treatment is a treatment for swelling a rubber layer and impregnating a low friction material usable in the surface coating treatment between molecules.
The tube-hanging is a process in which a tube made of PTFE or other resin having a sliding property is directly coated on the rubber layers 65a and 65b of the pressure-bonding rollers 64a and 64b, and the tube is thermally contracted or an adhesive is used. Thus, it can be fixed to the pressure rollers 64a and 64b.
These treatments are preferably performed at least on the pressure roller 64a in contact with the photosensitive film 12, and are not necessarily performed on both the pressure rollers 64a and 64b.

  A tip cutting mechanism 74 that cuts the tip of the photosensitive film 12 at the start of operation and an inter-substrate cutting mechanism 76 that cuts the photosensitive film 12 between the glass substrates 14 are disposed on the downstream side of the pressure bonding mechanism 44. Has been. A film transport roller 78 is provided between the pressure rollers 64a and 64b and the tip cutting mechanism 74 to draw out the photosensitive film 12 at the start of operation. A substrate transport roller 80 for transporting the glass substrate 14 to which the photosensitive film 12 has been pressure-bonded is disposed.

  In this laminated body manufacturing apparatus, the photosensitive film 12 supplied from the film roll 22 is conveyed to the processing mechanism 26, and the protective film 20 and the photosensitive resin layer 18 are made to have a predetermined length by the round blade 24 leaving the temporary support 16. After being cut every time, the label is adhered to the protective film 20 of the photosensitive sheet film 12 in which the half cut portions 27a and 27b are formed, and the photosensitive sheet film 12 to which the label is adhered is attached to the peeling mechanism 38. Supplied. At this time, as shown in FIG. 2, the photosensitive film 12 has a length L of the photosensitive resin layer 18 that is pressure-bonded to the glass substrate 14 and a width of the protective film 20 b that remains between the glass substrates 14. Slit-shaped half-cut portions 27a and 27b are formed at intervals corresponding to M. In addition, the label is bonded to the protective film 20 a that is peeled off from the photosensitive film 12 at both ends with the middle portion being non-adhered to the protective film 20 b. Then, the photosensitive film 12 from which the protective film 20a is peeled off and the photosensitive resin layer 18 is partially exposed is supplied between the pressure-bonding rollers 64a and 64b in a separated state, and is heated to a predetermined temperature by the substrate heating unit 66. The heated glass substrate 14 is supplied between the pressure rollers 64a and 64b. And the photosensitive resin layer 18 is crimped | bonded to the predetermined position of the glass substrate 14 by conveying the photosensitive film 12 and the glass substrate 14 by pressurizing and heating with the pressurizing rollers 64a and 64b.

  In addition, the description of Unexamined-Japanese-Patent No. 2006-23407 can be referred for the further detail of the laminated body manufacturing apparatus shown in FIG.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to the following examples unless it exceeds the gist thereof. Unless otherwise specified, “part” is based on mass.

Example 1
-Preparation of photosensitive transfer material-
As a temporary support, polyethylene terephthalate (PET; hereinafter referred to as a PET temporary support) having a length of 400 m, a width of 1290 mm, and a thickness of 75 μm is prepared, and the following acrylic primer is used on one surface thereof to conduct electricity. The layer forming coating solution 1 was applied and dried, and further the protective layer forming coating solution 2 was applied and dried.
Acrylic primer
<Coating layer forming coating solution 1>
-Acrylic resin having a plurality of carboxylic acid groups 30.9 parts (Julimer ET-410, number average molecular weight 9700, weight average molecular weight 17000, solid content concentration 30% by mass, manufactured by Nippon Pure Chemical Co., Ltd.)
Melamine resin cross-linking agent 3.2 parts (Beccamin M-3, solid content concentration 80% by mass; manufactured by Dainippon Ink & Chemicals, Inc.)
-Tin oxide-antimony oxide conductive dispersion TDL-1 154.1 parts (TDL-1, solid concentration 17%, manufactured by Mitsubishi Materials Corporation)
-Surfactant: 0.73 parts (Narrow Acty HN-100, manufactured by Sanyo Chemical Industries)
・ Surfactant: 1.44 parts (Sandet BL, solid content concentration: 43% by mass, manufactured by Sanyo Chemical Industries)
・ Water ... 824.4 parts

<Protective layer forming coating solution 2>
・ Polyethylene latex ・ ・ ・ 17.8 parts (Chemipearl S120, solid content concentration 27% by mass, manufactured by Mitsui Chemicals, Inc.)
Colloidal silica: 11.8 parts (Snowtex C, solid content concentration 20% by mass, manufactured by Nissan Chemical Co., Ltd.)
・ Epoxy curing agent: 1.7 parts (Denacol EX-614B, manufactured by Nagase Chemical Co., Ltd.)
・ Surfactant: 0.52 parts (Narrow Acty HN-100, manufactured by Sanyo Chemical Industries)
-Surfactant: 0.59 parts (Sandet BL, solid content concentration: 43% by mass, manufactured by Sanyo Chemical Industries)

  Next, on the surface of the acrylic temporary primer non-coated surface of the PET temporary support, a cushion layer coating solution having the following composition was applied so that the dry layer thickness was 14.6 μm, and dried to form a cushion layer. On the cushion layer, an intermediate layer coating solution having the following composition was applied and dried to a dry layer thickness of 1.6 μm, and the intermediate layer was laminated. On the laminated intermediate layer, a photosensitive resin layer coating solution having the following composition was further applied and dried to a dry layer thickness of 1.3 μm to form a photosensitive resin layer. The formed photosensitive resin layer A polypropylene film (protective film) having a thickness of 12 μm was pressure-bonded to the surface of the film to obtain a photosensitive transfer material.

<Composition of coating solution for cushion layer>
Methanol: 11.1 parts Propylene glycol monomethyl ether acetate: 6.36 parts Methyl ethyl ketone: 52.4 parts Methyl methacrylate / 2-ethylhexyl acrylate / benzyl methacrylate / methacrylic acid copolymer (co-polymer) Polymer composition ratio (molar ratio) = 55 / 11.7 / 4.5 / 28.8, molecular weight = 100,000, Tg≈70 ° C.) 6.80 parts styrene / acrylic acid copolymer (copolymerization) Composition ratio (molar ratio) = 63/37, average molecular weight = 10,000, Tg≈100 ° C.... 10.2 parts 2,2-bis [4- (methacryloxypolyethoxy) phenyl] propane (Shin Nakamura Chemical Industry Co., Ltd.) 9.1 parts 30% by mass MEK solution of the following surfactant 1 0.54 parts

* Surfactant 1
MegaFuck F-780-F (trade name; manufactured by Dainippon Ink & Chemicals, Inc.)
Composition: C ₆ F ₁₃ CH ₂ CH ₂ OCOCH═CH ₂ (40 parts) and H (OCH (CH ₃ ) CH ₂ ) ₇ OCOCH═CH ₂ (55 parts) and H (OCH ₂ CH ₂ ) ₇ OCOCH═CH ₂ (5 parts) copolymer (weight average molecular weight 30,000)

<Composition of coating solution for intermediate layer>
PVA205 (polyvinyl alcohol, manufactured by Kuraray Co., Ltd., degree of saponification = 88%, degree of polymerization 550)... 32.2 parts Parts ・ Distilled water ・ ・ ・ 524 parts ・ Methanol ・ ・ ・ 429 parts

<Composition of coating solution for photosensitive resin layer>
Carbon black (Color Black FW2, manufactured by Degussa) 26.7 parts Dispersant 3.3 parts (Disparon DA7500 (acid value 26, amine value 40), manufactured by Enomoto Kasei Co., Ltd.)
Benzyl methacrylate / methacrylic acid (= 72/28 [molar ratio]) copolymer (weight average molecular weight = 30,000, 50% by mass solution of propylene glycol monomethyl ether acetate)... 10 partsPropylene glycol monomethyl ether acetate ... 60 copies

-Preparation of transfer device-
A transfer device having the same structure as that shown in FIG. 1 was prepared. As the pressure rollers 64a and 64b constituting the pressure-bonding mechanism 44 constituting the transfer device, a hollow core roll made of STKM 13A and a silicone rubber layer (rubber layer) formed by coating the entire curved surface of the core roll with silicone ) A rubber-covered roller composed of 65a and 65b was used. The pressure roller 64a is a drive roller, and both the pressure rollers 64a and 64b are heated.

-Fabrication of laminates-
By preparing a glass substrate having a length of 1300 mm, a width of 1200 mm, and a thickness of 0.7 mm as a substrate, loading the photosensitive transfer material obtained above into a transfer device, and performing pressure bonding and peeling transfer under the following pressure bonding conditions A laminate was produced. In this way, when pressure bonding and peeling transfer were continued for 25000 m, meandering was observed as the number of transferred sheets increased.
<Crimping conditions>
-Linear pressure in the axial direction of the pressure rollers 64a and 64b: 150 [N / cm]
・ Conveying speed of the pressure rollers 64a and 64b: 1.4 [m / min]
-Heating temperature of the pressure rollers 64a and 64b: 130 [° C.]
The contact angle of the photosensitive film 12 hung on the outer periphery of the pressure roller 64a: 90 [°]
-Heating temperature of the glass substrate by the substrate heating unit 66: 120 [° C]
Glass substrate size: width 1100 x length 1300 x thickness 0.7 [mm]
・ Tension of photosensitive film: 140 [N / width 1090 mm]

-Evaluation 1 (Lami foam, light and shade unevenness)-
In the above, after pressing and peeling transfer of 25000 m, the surface of the rubber layer 65a of the pressing roll 64a that has started to meander due to the accumulation of the number of transferred sheets is washed with ethanol, and the static friction coefficient is adjusted to press and peel. The following method evaluated the presence or absence of the generation | occurrence | production of the lami bubble (bubble mixing) and density unevenness when 10 sheets of transfer were performed. The evaluation results are shown in Table 1 below.

Specifically, the average value of the static friction coefficient of the pressure roller 64a and the relative standard deviation of the static friction coefficient are adjusted, and the laminate state of the photosensitive resin layer is visually observed with an optical microscope after peeling transfer in each case. The presence or absence of the occurrence of lamellar bubbles and density unevenness in the photosensitive resin layer was evaluated according to the following evaluation criteria. Here, the shading unevenness was evaluated based on whether or not streaky unevenness generated in parallel with the pressure roller is generated.
<Evaluation criteria for Lami foam>
○: No generation of lami bubbles was observed in all 10 sheets.
Δ: Out of 10 sheets, generation of lami bubbles concentrated on some glass substrates was confirmed, which was in an unacceptable range for practical use.
X: The generation | occurrence | production of the Lami foam dense to all 10 sheets was confirmed, and it had a problem in quality.
<Evaluation criteria for shading unevenness>
◯: Generation of stripe-like shading unevenness was not observed in all 10 sheets.
Δ: Streaky shading unevenness was confirmed on some of the 10 glass substrates, and was in an unacceptable range for practical use.
X: Streaky shading unevenness was confirmed on all 10 sheets, resulting in a problem in quality.

  As shown in Table 1, the present invention was able to maintain high quality lami quality. In addition, by cleaning so that the relative standard deviation (coefficient of variation) of the static friction coefficient in the width direction of the static friction coefficient does not increase significantly, the quality of the laminate was stably maintained over a long period of time.

-Evaluation 2 (Lamination of foam / cushion layer)-
In the above, after the 25,000-m pressure bonding and peeling transfer, the static friction coefficient is adjusted while cleaning the surface of the rubber layer 65a of the pressure-bonding roll 64a that has started to meander due to the accumulation of the number of transfer sheets using ethanol, and the photosensitive sheet film After changing the tension of 12 and performing 10 sheets of pressure bonding and peeling transfer, peeling off the temporary support, the laminated state was observed with an optical microscope, and the presence or absence of lami bubbles (bubbles mixed) and peeling of the cushion layer were as follows: Evaluation was performed according to the evaluation criteria. The evaluation results are shown in Table 2 below.
<Evaluation criteria for Lami foam>
○: No generation of lami bubbles was observed in all 10 sheets.
Δ: Out of 10 sheets, generation of lami bubbles concentrated on some glass substrates was confirmed, which was in an unacceptable range for practical use.
X: The generation | occurrence | production of the Lami foam dense to all 10 sheets was confirmed, and it had a problem in quality.
<Evaluation criteria for peeling the cushion layer>
○: No occurrence of 10 sheets.
X: Generation | occurrence | production was confirmed even in 1 sheet in 10 sheets.

  The film tension was measured under an environment of 25 ° C. and 55% RH.

  As shown in Table 2 above, the occurrence of lami bubbles worsens with a decrease in static friction coefficient, and when the static friction coefficient decreases, wrinkles are generated even if the tension applied to the photosensitive film is set high. It was not possible to avoid quality deterioration due to mixing and peeling of the cushion layer.

It is a schematic block diagram which shows an example of the laminated body manufacturing apparatus which can be used for implementation of the manufacturing method of the laminated body of this invention. It is a schematic sectional drawing which shows the cross-section of a photosensitive film. It is a schematic sectional drawing which shows the state which transcribe | transferred the photosensitive film to the glass substrate. It is explanatory drawing for demonstrating the measuring method of a static friction coefficient.

Claims (4)

  When the average value of the coefficient of static friction with respect to the temporary support of the pressure roller for pressing the wide transfer material having the transfer layer on the temporary support to the substrate is in the range of 0.25 to 0.7, The transfer roller is transferred to the substrate by pressing the pressure roller in contact with the support while maintaining the relative standard deviation of the coefficient of static friction in the axial center direction at 0.25 or less and peeling the temporary support after pressing. A method for manufacturing a laminate, which produces a laminate.   The method for manufacturing a laminate according to claim 1, wherein a surface of the pressure roller in contact with the temporary support is a rubber material.   The method for producing a laminate according to claim 1 or 2, wherein the pressure bonding is performed by heating the pressure roller in a range of 80 to 150 ° C.   The transfer layer is a thermoplastic photosensitive resin layer exhibiting a viscosity characteristic in a range of 30 to 30000 Pa · s when heated to a range of 80 to 150 ° C. by the pressure roller. The manufacturing method of the laminated body of any one of Claim 3.

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